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Engine 5.4L: Assembly: Engine: Assembly

NOTE: During engine assembly it may become necessary to check bearing clearances, end play etc. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  1. Read the first character code information on the cylinder block face (1) and record the information.
    Fig 1: Identifying Character Code Location
    G03570723Courtesy of FORD MOTOR CO.
  2. Read the first character on the No. 7 crankshaft counterweight and note it.
    Fig 2: Identifying First Character Location
    G03570724Courtesy of FORD MOTOR CO.
  3. Using the data recorded in the previous two steps, cross-reference using the chart to obtain bearing grade.
    Fig 3: Bearing Grade Chart
    G03570725Courtesy of FORD MOTOR CO.
    4. NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
    Fig 4: Installing Crankshaft Main Bearings Into Main Bearing Caps
    G03570726Courtesy of FORD MOTOR CO.
  4. Lubricate the crankshaft main bearings with clean engine oil and install into the cylinder block. Install the crankshaft main bearings into the main bearing caps.
    5. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
    Fig 5: Installing Crankshaft Onto Upper Main Bearings
    G03570727Courtesy of FORD MOTOR CO.
  5. Install the crankshaft onto the upper main bearings.
    6. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
    Fig 6: Installing Crankshaft Thrust Washer At Back Of No. 5 Main Boss
    G03570728Courtesy of FORD MOTOR CO.
  6. Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.
    7. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
    Fig 7: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss
    G03570729Courtesy of FORD MOTOR CO.
  7. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
    8. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the rear of the engine.
    NOTE: To aid in assembly apply petroleum jelly to the back of the crankshaft thrust washer.
    Fig 8: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap
    G03570730Courtesy of FORD MOTOR CO.
  8. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with the oil grooves facing the crankshaft surface.
  9. Install the crankshaft lower main bearings into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or deadblow hammer.
    Fig 9: Installing Crankshaft Lower Main Bearings Into Main Bearing Caps
    G03570731Courtesy of FORD MOTOR CO.
    10. NOTE: Crankshaft not shown for clarity.
    Fig 10: Installing Main Bearing Cap Dowel Pins
    G03570732Courtesy of FORD MOTOR CO.
  10. Install the main bearing cap dowel pins so the flat sides face the crankshaft.
    11. NOTE: Crankshaft not shown for clarity.
  11. Install and tighten the new bolts in two stages:
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 11: Tightening Bolts In Sequence
      G03570733Courtesy of FORD MOTOR CO.
    12. NOTE: Crankshaft not shown for clarity.
  12. Install and tighten the new cross-mounted bolts in two stages:
    • Stage 1: Tighten to 30 N.m (22 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 12: Tightening Cross-Mounted Bolts
      G03570734Courtesy of FORD MOTOR CO.
    13. NOTE: Verify the connecting rods and rod caps for correct orientation.
    NOTE: Carefully tap the connecting rod bolts in. Avoid damaging the connecting rod.
  13. Prepare the connecting rod and caps.
    • Insert the bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.
      Fig 13: Inserting Upper And Lower Rod Bearings Into Rod And Cap
      G03570735Courtesy of FORD MOTOR CO.
    14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    NOTE: Make sure the piston arrow is facing forward.
  14. Using the special tools, install the No. 1 and No. 6 piston and connecting rod assemblies.
    • Lubricate the piston and ring with clean engine oil.
    • Lubricate the rod bearings with clean engine oil.
      Fig 14: Lubricating Rod Bearings
      G03570736Courtesy of FORD MOTOR CO.
  15. Seat the connecting rods on the crankshaft journals and remove the special tools.
    Fig 15: Seating Connecting Rods On Crankshaft Journals
    G03570737Courtesy of FORD MOTOR CO.
    16. CAUTION: The rod bearing caps must keep the same orientation as marked during disassembly.
    NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time repaired.
    NOTE: Rotate the crankshaft after each connecting rod is installed and tightened, to check for assembly binding.
    Fig 16: Installing Rod Bearing Caps
    G03570738Courtesy of FORD MOTOR CO.
  16. Install the rod bearing caps and tighten the bolts in three stages:
    • Stage 1: Tighten to 25 N.m (18 lb-ft).
    • Stage 2: Tighten to 45 N.m (30 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
  17. Install the piston connecting rod assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
  18. Position the oil pump and gasket and install the bolts in the sequence shown.
    Fig 17: Installing Oil Pump
    G03570739Courtesy of FORD MOTOR CO.
  19. Install and tighten the oil pump screen and cover spacer.
    Fig 18: Installing Oil Pump Screen And Cover Spacer
    G03570740Courtesy of FORD MOTOR CO.
    20. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
    Fig 19: Installing Oil Pump Screen Cover And Tube, And Bolts
    G03570741Courtesy of FORD MOTOR CO.
  20. Install the oil pump screen cover and tube, and the bolts.
  21. Install the cylinder head gaskets.
    Fig 20: Installing Cylinder Head Gaskets
    G03570742Courtesy of FORD MOTOR CO.
  22. Install the LH and the RH cylinder heads. Loosely install the new bolts.
    Fig 21: Installing LH And RH Cylinder Heads
    G03570743Courtesy of FORD MOTOR CO.
  23. Tighten the LH and RH bolts in three stages, in the sequence shown.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
      Fig 22: Tightening LH And RH Bolts In Sequence
      G03570744Courtesy of FORD MOTOR CO.
  24. Install RH exhaust manifold gaskets and the exhaust manifold.
    • Tighten the nuts in the sequence shown.
      Fig 23: Installing RH Exhaust Manifold
      G03570745Courtesy of FORD MOTOR CO.
    25. CAUTION: Timing chain procedures must be followed exactly or damage to the pistons or valves can result.
    Fig 24: Compressing Tensioner Plunger
    G03570746Courtesy of FORD MOTOR CO.
  25. Compress the tensioner plunger, using the edge of a soft-jawed vise.
  26. Install a paper clip into the hose in the tensioner housing to hold the ratchet assembly.
    • Remove the tensioner from the vise.
    Fig 25: Removing Tensioner From Vise
    G03570747Courtesy of FORD MOTOR CO.
    27. NOTE: There are 61 links in the timing chain.
    Fig 26: Identifying Copper Links Position
    G03570748Courtesy of FORD MOTOR CO.
  27. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
  28. Install the timing chain guides.
    Fig 27: Installing Timing Chain Guides
    G03570749Courtesy of FORD MOTOR CO.
  29. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o'clock position.
    Fig 28: Identifying LH Camshaft Sprocket Timing Mark Position
    G03570750Courtesy of FORD MOTOR CO.
    30. NOTE: LH shown, RH similar.
    Fig 29: Installing Special Tools On LH And RH Cylinder Heads
    G03570751Courtesy of FORD MOTOR CO.
  30. Install the special tools on the LH and RH cylinder heads.
  31. Using the special tool, position the crankshaft.
    Fig 30: Installing Crankshaft
    G03570752Courtesy of FORD MOTOR CO.
  32. Remove the special tool.
  33. Install the crankshaft sprocket with the timing mark facing outward.
    Fig 31: Installing Crankshaft Sprocket With Timing Mark Position
    G03570753Courtesy of FORD MOTOR CO.
  34. Install the LH and RH timing chain onto the crankshaft and camshaft sprockets.
    • Align the two copper (marked) links with the timing mark on the camshaft sprocket.
    • Align the one copper-colored link with the timing mark on the crankshaft sprocket.
      Fig 32: Aligning One Copper-Colored Link With Timing Mark On Crankshaft Sprocket
      G03570754Courtesy of FORD MOTOR CO.
    35. NOTE: LH shown, RH similar.
    Fig 33: Installing Tensioner Arms And Tensioners
    G03570755Courtesy of FORD MOTOR CO.
  35. Position the tensioner arms and tensioners, and install the bolts.
  36. Remove the paper clip.
    Fig 34: Removing Paper Clip
    G03570756Courtesy of FORD MOTOR CO.
  37. Verify the camshaft and crankshaft sprocket to copper link alignment.
    Fig 35: Identifying Copper Link Alignment Position
    G03570757Courtesy of FORD MOTOR CO.
    38. NOTE: LH shown, RH similar.
    Fig 36: Removing Special Tools From LH And RH Cylinder Heads
    G03570758Courtesy of FORD MOTOR CO.
  38. Remove the special tools from the LH and RH cylinder heads.
  39. Position the camshaft lobes at the base circle.
  40. Using the special tool, compress the exhaust valve springs and install the roller followers.
    Fig 37: Compressing Exhaust Valve Springs
    G03570759Courtesy of FORD MOTOR CO.
  41. Using the special tool, compress the intake valve springs and install the roller followers.
    Fig 38: Compressing Intake Valve Springs
    G03570760Courtesy of FORD MOTOR CO.
  42. Repeat the previous steps to install all roller followers.
  43. Position the crankshaft sensor ring on the crankshaft.
    Fig 39: Installing Crankshaft Sensor Ring On Crankshaft
    G03570761Courtesy of FORD MOTOR CO.
  44. Apply silicone gasket sealant in the locations shown.
    Fig 40: Applying Silicone Gasket Sealant
    G03570762Courtesy of FORD MOTOR CO.
  45. Position the engine front cover and install the bolts and the studs in three stages:

    Stage 1: Tighten numbers one through five to 25 N.m (18 lb-ft).

    Stage 2: Tighten numbers six and seven to 50 N.m (37 lb-ft).

    Stage 3: Tighten numbers 11 through 15 to 25 N.m (18 lb-ft).

    ITEM DESCRIPTION

    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex-Head Pilot, M10 x 1.5 x 30
    7 N808529 Stud, Hex-Head Pilot, M10 x 1.5 x 30
    8 N806177 Bolt, Hex-Head Flange, M8 x 1.25 x 50
    9 N806177 Bolt, Hex-Head Flange, M8 x 1.25 x 50
    10 N806177 Bolt, Hex-Head Flange, M8 x 1.25 x 50
    11 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 - M8 x 1.25 x 27
    12 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 - M8 x 1.25 x 27
    13 W705386 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65
    14 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 - M8 x 1.25 x 27
    15 W705386 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65
    Fig 41: Installing Engine Front Cover
    G03570763Courtesy of FORD MOTOR CO.
  46. Apply silicone gasket sealant in the locations shown.
    Fig 42: Applying Silicone Gasket Sealant In Engine Front Cover
    G03570764Courtesy of FORD MOTOR CO.
    47. NOTE: LH shown, RH similar.
    Fig 43: Installing Valve Covers
    G03570765Courtesy of FORD MOTOR CO.
  47. Install the valve covers, the bolts, and the studs.
    1. Install the gaskets.
    2. Install the valve covers.
    48. NOTE: LH shown, RH similar.
    Fig 44: Installing Spark Plugs
    G03570766Courtesy of FORD MOTOR CO.
  48. Install the eight spark plugs.
  49. Install the bolt and the belt idler pulley.
    Fig 45: Installing Bolt And Belt Idler Pulley
    G03570767Courtesy of FORD MOTOR CO.
  50. Using the special tools, install the front crank seal.
    Fig 46: Installing Front Crank Seal
    G03570768Courtesy of FORD MOTOR CO.
    51. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.
    Fig 47: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03570769Courtesy of FORD MOTOR CO.
  51. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  52. Using the special tool, install the crankshaft pulley.
    Fig 48: Installing Crankshaft Pulley
    G03570770Courtesy of FORD MOTOR CO.
  53. Install the bolt and washer. Tighten the bolt in four stages:
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 49: Installing Bolt And Washer
    G03570771Courtesy of FORD MOTOR CO.
  54. Install the water pump.
    • Inspect and lube the water pump O-ring seal before installation.
      Fig 50: Installing Water Pump
      G03570772Courtesy of FORD MOTOR CO.
  55. Install the four bolts.
    Fig 51: Installing Bolts
    G03570773Courtesy of FORD MOTOR CO.
  56. Install the water pump pulley and the bolts.
    Fig 52: Installing Water Pump Pulley And Bolts
    G03570774Courtesy of FORD MOTOR CO.
  57. Install the heater return tube and the bolt.
    • Inspect and lube the O-ring seals.
      Fig 53: Installing Heater Return Tube And Bolt
      G03570775Courtesy of FORD MOTOR CO.
  58. Install the knock sensor (KS).
    Fig 54: Installing Knock Sensor
    G03570776Courtesy of FORD MOTOR CO.
  59. Install the wiring and connect to the engine at six locations.
    Fig 55: Installing Wiring And Connecting To Engine
    G03570777Courtesy of FORD MOTOR CO.
  60. Connect the KS.
    Fig 56: Connecting Knock Sensor
    G03570778Courtesy of FORD MOTOR CO.
  61. Install the RH ignition coils.
    Fig 57: Installing RH Ignition Coils
    G03570779Courtesy of FORD MOTOR CO.
  62. Connect the RH ignition coils.
    Fig 58: Connecting RH Ignition Coils
    G03570780Courtesy of FORD MOTOR CO.
  63. Install the RH ignition coil cover.
    Fig 59: Installing RH Ignition Coil Cover
    G03570781Courtesy of FORD MOTOR CO.
  64. Position the bracket and the ground strap and install the nuts.
    Fig 60: Installing Bracket And The Ground Strap
    G03570782Courtesy of FORD MOTOR CO.
  65. Connect the cylinder head temperature (CHT) sensor.
    Fig 61: Connecting Cylinder Head Temperature Sensor
    G03570783Courtesy of FORD MOTOR CO.
  66. Connect the camshaft position (CMP) sensor.
    Fig 62: Connecting Camshaft Position Sensor
    G03570784Courtesy of FORD MOTOR CO.
  67. Install the LH ignition coils.
    Fig 63: Installing LH Ignition Coils
    G03570785Courtesy of FORD MOTOR CO.
  68. Connect the LH ignition coils.
    Fig 64: Connecting LH Ignition Coils
    G03570786Courtesy of FORD MOTOR CO.
  69. Install the bolts and the LH ignition coil cover.
    Fig 65: Installing Bolts And LH Ignition Coil Cover
    G03570787Courtesy of FORD MOTOR CO.
  70. Install the oil fill tube.
    Fig 66: Installing Oil Fill Tube
    G03570788Courtesy of FORD MOTOR CO.
  71. Connect the oil pressure sender.
    Fig 67: Connecting Oil Pressure Sender
    G03570789Courtesy of FORD MOTOR CO.
    72. NOTE: LH shown, RH similar.
    Fig 68: Installing Cylinder Block Drain Plugs
    G03570790Courtesy of FORD MOTOR CO.
  72. Install the cylinder block drain plugs.
    73. NOTE: RH shown, LH similar.
    Fig 69: Installing Left And Right Engine Mounts
    G03570791Courtesy of FORD MOTOR CO.
  73. Install the left and right engine mounts.
    74. NOTE: LH shown, RH similar.
    Fig 70: Installing Special Tool
    G03570792Courtesy of FORD MOTOR CO.
  74. Install the special tool.
  75. Remove the engine from the work stand.
    Fig 71: Removing Engine From Work Stand
    G03570793Courtesy of FORD MOTOR CO.
    76. NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: The silicone must be applied on the groove along the retainer plate.
    Fig 72: Applying Bead Of Silicone Gasket And Sealant Around Rear Oil Seal Retainer Sealing Surface
    G03570794Courtesy of FORD MOTOR CO.
  76. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
  77. Install the rear oil seal retainer and loosely install the six bolts.
    Fig 73: Installing Rear Oil Seal Retainer
    G03570795Courtesy of FORD MOTOR CO.
  78. Tighten the bolts in the sequence shown.
    Fig 74: Tightening Bolts In Sequence
    G03570796Courtesy of FORD MOTOR CO.
    79. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 75: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
    G03570797Courtesy of FORD MOTOR CO.
  79. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
    80. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 76: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
    G03570798Courtesy of FORD MOTOR CO.
  80. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
  81. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
    Fig 77: Installing Oil Pan Gasket And Oil Pan
    G03570799Courtesy of FORD MOTOR CO.
  82. Tighten the bolts in three stages, in the sequence shown.
    • Stage 1: Tighten to 2 N.m (18 lb-in).
    • Stage 2: Tighten to 20 N.m (15 lb-ft).
    • Stage 3: Tighten an additional 60 degrees.
      Fig 78: Tightening Bolts In Sequence
      G03570800Courtesy of FORD MOTOR CO.
  83. Lower the engine onto wooden blocks.
  84. Remove the special tool.
    Fig 79: Removing Special Tool
    G03570801Courtesy of FORD MOTOR CO.
  85. Install the oil level indicator and tube, and the stud.
    Fig 80: Installing Oil Level Indicator And Tube, And Stud
    G03570802Courtesy of FORD MOTOR CO.
  86. Install the LH exhaust manifold and gaskets.
    • Tighten the nuts in the sequence shown.
      Fig 81: Installing LH Exhaust Manifold And Gaskets
      G03570803Courtesy of FORD MOTOR CO.
  87. Install the special tool and raise the engine.
    Fig 82: Raising Engine
    G03570804Courtesy of FORD MOTOR CO.
  88. Using the special tool, install the crankshaft rear oil seal.
    Fig 83: Installing Crankshaft Rear Oil Seal
    G03570805Courtesy of FORD MOTOR CO.
  89. Using the special tool, install the crankshaft oil slinger.
    Fig 84: Installing Crankshaft Oil Slinger
    G03570806Courtesy of FORD MOTOR CO.
  90. Install the spacer plate.
    Fig 85: Installing Spacer Plate
    G03570807Courtesy of FORD MOTOR CO.
  91. Install the bolts and the flywheel.
Fig 86: Installing Bolts And Flywheel
G03570808Courtesy of FORD MOTOR CO.
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